Prefabricated roofing construction and method



Sept. 23, 1969 w. .1. WARNER 3,468,086

PREFABRICATED ROOFING CONSTRUCTION AND METHOD Filed April 9. 1968INVENTOR WALTER J WARNER ATTORNEYS United States Patent 3,468,086PREFABRICATED ROOFING CONSTRUCTION AND METHOD Walter J. Warner,Westford, Vt., assignor to The A.C.

Hathorne Company, South Burlington, Vt., a corporation of Vermont FiledApr. 9, 1968, Ser. No. 719,947

Int. Cl. E04d 3/24 U.S. Cl. 52173 Claims ABSTRACT OF THE DISCLOSURE Thepresent invention provides a prefabricated roofing panel having a panelcore and sheet material adhered to one face of the panel core to formthe weather surface of the panel. Each panel is generally rectangularand two adjacent edges of the sheet extend beyond corresponding panelcore edges to form flaps. To protect the flaps, the long flap is foldedback and taped to the outer face of the sheet material, the tapecovering the-preapplied adhesive disposed on the underface of the fiap.The second flap, including the end portions of the first folded flap, isalso folded back and taped to the outer face of the sheet material. Wheninstalling the roof panels, the tapes are re leased and the flaps areunfolded to overlie adjacent roof panels to form a complete weathersurface for the entire roof structure with the flaps adhered to adjacentpanels.

BACKGROUND OF THE INVENTION The present invention relates toprefabricated building structures and particularly relates to a methodand apparatus for protecting, prior to use, the flaps on roof panels ofthe type having outer weatherized sheet material projecting beyond thepanel edges to form flaps for overlying and forming weather seals withthe adjacent roofing panels.

With the advent of prefabricated, oftentimes lightweight,

roofing panels, there has arisen the need for effective methods andapparatus for installing the roof panels to form a completed roofstructure, particularly in a manner to concurrently provide an effectiveweatherproof surface. Current roof panels of the prefabricated type andwhich may comprise expanded polystyrene foam, combinations of asbestos,and cement, or the like, are usually secured along their edges one tothe other by an interlocking or grouted joint or the like to form acompleted roof structure. Once the panels are assembled, sheets ofweather resistant material, for example, sheets of bituminous roofingpaper, are often applied to the assembled panels to provide a completeweather resistant roof surface. This, however, requires additional timeand labor which adds to the cost of the completed roof structure.

In some instances, prefabricated roof panels have been formed withweather resistant sheet material preadhered to the panels prior toinstallation. The preadhered sheet material usually lies coextensivewith the panel, that is, the edges of the sheet material lie flush withthe edges of the panel. An additional operation is therefore required toweather seal the roofing panels at their joints. In US. Patent No.3,111,787, this problem has to some extent been overcome. In thispatent, a panel is provided having a roofing sheet with a flap along anedge thereof which overlies and is adhesively secured to an adjacentpanel. Release paper is applied to the adhesive surface of the flap ofthe sheet material so that the adhesive is effective upon stripping therelease paper when the panels are installed. However, it has been foundthat the flap on prefabricated panels of this type are easily damagedduring handling, transit and installation. Often the flap is torn,

'ice' punctured or otherwise damaged whereby an effective We atherproofseal with an adjoining panel cannot be made.

SUMMARY OF THE PRESENT INVENTION The present invention provides aprefabricated, generally rectangular roofing panel having a panel coreand a Weather resistant sheet material preadhered to the core andforming the weather face of the panel. The sheet material is appliedconcurrently with the fabrication of the panel core and, as such, formsan integral part of the panel during all subsequent transportation,storage, handling and the like. The sheet material is adhered to andcompletely covers the outer face of the panel core in a manner providinga pair of adjacent edge portions or flaps which extend beyond thecorresponding panel core edges. The opposite edges of the sheet materiallie flush with the corresponding opposite edges of the panel core.During prefabrication of the panel, adhesive is applied to theundersurfaces of the flaps whereby, when the roof panels are installedto form a completed roof structure, the flaps overlie and may be adheredto the edge portions of adjacent panels.

In order to protect the flaps against puncture, tearing or other damagewhich may be caused during handling of the panels prior to installationand to protect the adhesive surface of the flaps, the flaps are foldedback onto the sheet material and tapes are applied to the adhesivesurfaces of the flaps to protect the same and to secure the flaps to thesheet material. In this manner, the sheet material is substantiallycoextensive with the panel core and the flaps are preclude-d fromprojecting beyond the lateral confines of the panel. This not onlyprotects the flaps against damage, but also facilitates panel handlingand storing.

Specifically, the flap along the long side of each panel is first foldedback. A tape coextensive in length with the fiap is applied to theadhesive surface of the latter and to an adjacent portion of theoverlyin sheet material to maintain the flap in the folded position. Theshort flap, as well as the folded end flap portion of the long flap, issimilarly folded back on the panel. A tape is applied to the adhesivesurface of the short flap, an adjacent portion of the sheet material,and a portion of the first folded flap to retain the short flap infolded position.

To provide a roof structure, the panels are arranged and joined toadjacent panels in a conventional manner to form a continuous roofsurface. The tapes may then be stripped from the flaps and the flapsfolded over onto adjacent panels and adhered thereto. In this manner, aneffective seal is provided at the juncture of the adjacent panels and acomplete weatherproof roof structure is thus formed.

Accordingly, it is a primary object of the present invention to providean improved prefabricated roofing panel.

It is another object of the present invention to provide a prefabricatedroofing panel of the type having a weather surface including flaps andextending beyond the edges of the panel for forming weather seals withadjoining panels wherein damage to the unprotected flaps duringhandling, transportation, and the like, of the panel prior to use isprecluded.

It is a related object of the present invention to provide aprefabricated roofing panel having the foregoing characteristics whereinthe adhesive coated undersurfaces of the flaps are fully protectedthroughout all phases of panel handling and remain tacky to facilitatefinal securement of the flaps to adjoining panels.

It is a further object of the present invention to provide a simple andinexpensive method of protecting the overlapping fiaps of weatherresistant sheet material of prefabricated roofing panels and theadhesive coated undersurfaces of the flaps whereby the flaps may bereadily and easily secured to form effective seals with adjoining roofpanels.

These and further objects and advantages of the present invention willbecome more apparent upon reference to the following specification,claims and appended drawings.

DESCRIPTION OF THE DRAWING FIGURES FIGURE 1 is a fragmentary perspectiveview of a roof structure employing the roof panel construction of thepresent invention;

FIGURE 2 is an enlarged fragmentary cross sectional view of a jointformed between adjacent panels and taken about on line 22 of FIGURE 1;

FIGURES 3-6 are perspective views illustrating the manner in which theweather resistant sheet material is folded back from the panel edges andthe tapes applied to retain the flaps in folded position; and

FIGURE 7 is an enlarged fragmentary cross sectional view of a panel edgeillustrating a flap retained in the folded position by a tape and takenabout on line 77 of FIGURE 6.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to the drawings andparticularly to FIGURES 1 and 2, there is shown a plurality ofprefabricated roofing panels 10 assembled and joined one to the otheralong their end and lateral edges to form a completed integral roofingstructure. Panels 10 may comprise a panel core, indicated at 12, havingsheet material 14 adhered along a face thereof and forming the weathersurface of panel 10. The materials comprising panel core 12 and sheet 14may comprise any of the well known roofing materials. For example, core12 may comprise a sandwiched plywood and foam core construction or maybe formed entirely of a plastic material such as a sheet of expandedpolystyrene. Sheet material 14 may comprise, for example, a plasticsheet, roofing felt, or any other type of material conventionallyemployed as weather resistant material. In the preferred embodiment,panel core 12 comprises a first and primary layer 16 of mineralizedfiber bound under pressure with portland cement and a second layer 18 ofsmooth concrete overlying the primary layer 16 and to which weatherresistant sheet material 14 is adhered. Sheet material 14 preferablycomprises a waterproof membrane, for example, the sheet material knownunder the trade name Tedlar, manufactured by the Du Pont Company.

In the illustrated form, panel cores 12 are preferably rectangular inshape with the long or lateral edges thereof stepped as at 20 wherebyoverlapping and interlocking joints between laterally adjacent panelsmay be formed. Other types of panel joints may, however, be employed.For example, the edges of the panels may be formed to provide bulb T andgrout joints or ship lap joints, or the like.

Referring now to FIGURES 3-6, it will be seen that sheet 14 is alsorectangular in shape and is cut to a length and width substantiallygreater than the length and width of panel core 12. An adhesive,preferably an adhesive of the elastomeric type, is applied to theundersurface of sheet 14, and the latter is applied against the uppersurface of panel core 12 or secondary layer 18 such that two adjacentedges 22 and 24 of sheet 14 lie flush with the corresponding edges ofpanel core 12. The opposite edges 26 and 28 of sheet 14 thus extendoutwardly of the corresponding edges of panel core 12 to form end andlateral flaps 30 and 32 respectively. It will be noted that the adhesiveis applied to the entire undersurface of sheet 14 and that, as seen inFIGURE 3, the undersurfaces of flaps 30 and 32 are accordingly alsocoated with adhesive.

To prevent damage to flaps 30 and 32 as by puncturing, tearing orotherwise damaging the same during panel handling, transit, storage,etc., it is a feature of the present invention that flaps 30 and 32 arefolded back onto panel 10 upon initial fabrication of the panel and in aparticular manner as will become clear with the flaps being retained inthe folded position until installation whereby the longitudinal, lateraland vertical confines of the panel with the flaps folded aresubstantially identical to the longitudinal, lateral and verticalconfines of panel core 12. concomitantly, the flaps 30 and 32 are foldedand retained in their folded position in a manner such that the adhesiveundersurfaces of flaps 30 and 32 are fully protected and retain theiradhesive qualities throughout panel handling, storage, etc., whereby theflaps are readily and easily joined to and form high integritywaterproof seals with adjoining panels when installed in a manner aswill be presently set forth.

To these ends and as illustrated in FIGURE 4, one of the flaps,preferably the longer fiap 32, is folded back to overlie the adjacentportion of the upper face of sheet 14 such that its fold or crease line36 lies substantially flush with the corresponding long edge of panelcore 12. Note that the portion 34 of flap 32 which projects beyond theend of panel core 12 is folded back to overlie an adjacent portion ofend flap 30 such that the fold or crease line 36 extends beyond the endof the panel for reasons which will become apparent. A stri of tape 38,which is coextensive in length with flap 32 and of a slightly largerwidth, is applied to the adhesive undersurface of fiap 32 (which in thefolded position thereof illustrated in FIGURES 4-6 is its upper surface)and a portion of the upper face of sheet 14 adjacent folded edge 28.Tape 38 preferably comprises a gummed paperback tape with the gummedtape surface extending lengthwise along one edge of the underside of thetape to adhere to the upper face of sheet 14. The remaining portion ofthe underside of the tape, that is, that portion engaging the adhesivesurface of flap 32, can be plain and devoid of gum. Other types of tapecan be employed, such as silicone treated tapes and including thosetapes which have a gum applied coextensively along their undersurfaces.

The remaining end flap 30 is then folded back to overlie sheet 14 suchthat its crease or fold line 40' lies substantially flush along the endedge of panel core 12. Note that the end portion 34 of flap 32, togetherwith the end portion of tape 38 which overlies portion 34, are alsofolded back with end flap 30 about its crease line 40. A tape 42 havinga length equal to the width of panel core 12 and a width slightly largerthan the width of flap 30 is applied to the adhesive undersurface offlap 30 (which in the folded position thereof illustrated in FIGURES 5and 6 is its upper surface), a portion of the upper face of sheet 14 anda portion of tape 38. Tape 42 is similar to tape 38 in that only thelengthwise extending edge portion which overlies the adjacent portion ofsheet 14 need have a gummed surface, the remaining undersurface of tape42 being plain paper. In this manner, flaps 30 and 32 now liesubstantially within the longitudinal, lateral, and vertical confines ofcore panel 12 with the adhesive surfaces thereof fully protected wherebythe completed panel 10 may be shipped, stored, or otherwise handledwithout the danger of puncturing, tearing, etc., the flaps.

To assemble panels 10 and form a completed weatherproof, high integrityroof structure, panels 10 are mounted on supports, not shown, with theirlateral edges interlocking as at 20. Tapes 42 and 38 are successivelystripped from the adhesive surfaces of flaps 30 and 32, respectively,and the adjacent portions of sheet 14 whereby the flaps can be foldedabout their respective fold or crease lines to overlie the lateral andend edge portions of adjacent panels. As the adhesive on theundersurface of flaps 30 and 32 has been protected and unexposedthroughout handling, storage, etc., by the tapes and thereby remainstacky, the flaps 30 and 32 can be pressed against the sheet material 14forming the upper surfaces of adjacent panels 10, forming Weatherproof,high integrity seals therewith.

A roller may be used for this purpose if desired. Note that by formingsheet 14 both longer and wider than panel core 12, the corner areas ofadjoining panels, as indicated at A in FIGURE 1, are completely coveredby flaps and 32 whereby additional sealing in the corner areas iseliminated.

While the size of the panel is limited only by convenience of handling,panels 10, in a preferred form hereof, are 96 inches long and 30 incheswide. Sheet material 14 is preferably 102 inches long and 36 incheswide, whereby flaps 30 and 32 have a 6 inch width. Tapes 38 and 42 arepreferably formed in lengths of 102 and 30 inches, respectively, and arepreferably 7 inches wide. With these tape dimensions, a 1 inch widegummed undersurface if preferably provided along a longitudinal edge ofthe tapes to adhere the tapes to the upper surface of sheet 14 aspreviously described. The remaining 6 inch width of tape is preferablydevoid of a gummed or adhesive material as the tapes 38 and 42 may bereleasably secured in overlying position on flaps 30 and 32 by theadhesive provided on the undersurfaces of the latter flaps. It will beunderstood, however, that the undersurface of taps 38 and 42 may havegummed surface over their entire width.

As seen in FIGURES 1 and 2, an insulating material may be applied to theundersurface of the completed integral roof structure. Preferably, alayer of urethane insulation may be sprayed onto the undersurface ofpanel cores 12 providing a complete weatherproofed and insulated roofstructure.

It is thus seen that the objects of the present invention are fullyaccomplished in that there is provided a prefabricated roofing panelhaving a preadhered weather resistant surface including flap portionsextending beyond the panel to overlie adjacent panels when installed toform an effective weather seal therewith. By folding the flaps back inthe foregoing manner and retaining them in the folded positionthroughout handling, storage, transportation, etc., until finalinstallation of the panels, damage to the flaps which may affect theintegrity of the roof structure is avoided. Moreover, by taping theflaps back in the foregoing manner, the adhesive undersurfaces of theflaps are fully protected and remain tacky to form an effective sealwith the adjacent panels when the panels are in stalled to formcompleted roof structures.

What is claimed and desired to be secured by United States LettersPatent is:

1. A method of protecting the overlapping edge portions of flexiblesheets carried on the outer faces of building construction panelscomprising the steps of applying the sheet to a face of the panel suchthat at least a pair of adjacent edge portions of the sheet projectoutwardly beyond the corresponding edges of the panel forming a pair offlaps, folding both of said flaps back to overlie portions of the sheetwith their fold lines lying substantially flush along the correspondingedges of the panel and applying tapes to the upper faces of therespective folded flaps and to adjacent portions of the sheet to retainthe folded flaps in position overlying the sheet portions and back fromthe edges of the panel.

2. The method according to claim 1 including the steps of applyingprotective tapes along the upper faces of the respective folded flapsand along laterally adjacent portions of the sheet whereby the upperfaces of the folded flaps are covered entirely by the tapes.

3. The method according to claim 1 including first folding one of theflaps, applying tape along said one flap and along the adjacent portionof the sheet to retain said one flap in position overlying a portion ofthe sheet and back from the corresponding panel edge, then folding theother flap back such that it overlies both the adjacent portion of thesheet and a portion of the first folded flap, and applying a tape alongthe upper face of the other folded flap and along both the adjacentportions of the sheet and the upper face of the first folded flap toretain the second folded flap in position overlying the sheet and saidfirst flap portion.

4. The method according to claim 3 wherein said one flap is folded suchthat it overlies a portion of the sheet and an end portion thereofoverlies a portion of the unfolded second fiap, including the step offolding the second flap including the folded end portion of the firstflap as to overlie both an adjacent portion of said sheet and a portionof the first folded flap.

5. The method according to claim 4 including removing the tape from theupper faces of the flap and the adjacent portions of the sheet andrespectively folding said flaps in directions opposite to the directionin which they were first folded to overlie adjacent panels.

6. The method according to claim 3 including the step of applyingadhesive to the upper faces of the folded flaps prior to applying thetapes thereto, and applying the tapes to the folded flaps as to coversubstantially the entire adhesive coated upper faces of the folded flapsand removing the tapes from the adhesive coated faces whereby the fiapmay be located in overlying position and adhesively adhered to anadjacent panel.

7. A roofing panel comprising a panel core, a sheet of weather resistantmaterial, adhesive means for adhering said sheet to one face of saidpanel core, said sheet having at least one edge portion extending beyondthe corresponding edge portion of said panel core to form a flap, saidflap being folded back to overlie a portion of said sheet with the foldline lying substantially flush with said corresponding core panel edge,and means releasably securing said flap to said sheet to retain saidflap in folded overlying position relative to said sheet portion.

8. The roofing panel according to claim 7 wherein the undersurface ofsaid flap when lying in the extended position carries an adhesive, saidsecuring means including a tape overlying the adhesive surface of saidflap and an adjacent sheet portion when said flap lies in the foldedposition.

9. The roofing panel according to claim 7 wherein an adjacent edgeportion of said sheet material extends beyond the corresponding edgeportion of said panel core to form a second flap adjacent said firstflap, said second flap being folded back to overlie a portion of saidsheet with an end flap portion of said second flap overlying an adjacentend portion of the first flap, said second flap having a fold line lyingsubstantially flush with its corresponding panel core edge, and meansreleasably securing said second flap to said sheet to retain said secondflap in folded overlying position relative to the corresponding sheetportion.

10. The roofing panel according to claim 9 wherein the undersurfaces ofsaid flaps when lying in extended positions carry an adhesive material,said securing means including a pair of tapes overlying the adhesivesurfaces of the respective flaps and adjacent sheet portions when saidflaps lie in the folded position.

References Cited UNITED STATES PATENTS 1,849,869 3/1932 Fischer 525402,120,644 6/1938 Harper 52-447 2,303,737 12/1942 Hampson 52-4482,913,104 11/1959 Parker 20660 3,111,787 11/ 1963 Chamberlain 52420 X3,121,649 2/1964 Oliver 52-420 X ALFRED C. PERHAM, Primary Examiner US.Cl. X.R.

